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Fayat BOMAG BW 100 ADM-5, Operating Instruction

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Fayat BOMAG BW 100 ADM-5 Operating Instruction Download Page 61

Information sticker - Filler opening for hydraulic

oil

Information sticker - Engine oil drain

Information sticker - Disconnecting the battery

Information sticker - Ultra-low sulphur fuel

B-DEC-0214

Hydraulic Oil

Fig.  21

B-DEC-0211

Fig.  22

B-DEC-0219

Fig.  23

Fig.  24

Concerning your safety – Signage

 

BW 100 ADM-5

 

61

Summary of Contents for BOMAG BW 100 ADM-5

Page 1: ...BW 100 ADM 5 Tandem vibratory roller Operating Instruction Maintenance Instruction Original Operating Instructions S N 101 462 12 1553 01 2021 008 206 66 EN...

Page 2: ...ding toluene and benzene which are known to the State of California to cause cancer and birth defects or other reproductive harm WARNING Breathing diesel engine exhaust exposes you to chemicals known...

Page 3: ...25 3 2 2 Expert qualified person 25 3 2 3 Driver operator 26 3 3 Fundamentals for safe operation 27 3 3 1 Remaining dangers remaining risks 27 3 3 2 Regular safety inspections 27 3 3 3 Modifications...

Page 4: ...tion 46 3 7 5 Parking the machine 46 3 8 Refuelling 48 3 9 Emergency procedures 49 3 9 1 Actuating the emergency stop switch 49 3 9 2 Disconnecting the battery 49 3 9 3 Towing the machine 49 3 10 Main...

Page 5: ...ocket 75 4 2 3 Travel lever 76 4 2 4 Driver s seat 78 4 2 5 Throttle lever 79 4 3 Outside of machine 80 4 3 1 Water level gauge 80 4 3 2 Fuel level gauge 80 4 3 3 Main battery switch 80 4 3 4 Warning...

Page 6: ...6 6 6 ECONOMIZER 111 6 7 Water spraying system 114 6 8 ECOSTOP 115 6 9 Parking the machine in secured condition 117 6 10 Lifting lowering the edge cutter 119 6 11 Connecting disconnecting the hydraul...

Page 7: ...5 8 7 2 Checking and cleaning the water separator 155 8 8 Every 250 operating hours 157 8 8 1 Change engine oil and oil filter cartridge 157 8 8 2 Checking tensioning the V belt 159 8 8 3 Check the ai...

Page 8: ...184 8 13 1 Air filter maintenance 184 8 13 2 Cleaning the water spraying system 187 8 13 3 Measures if there is a risk of frost 188 8 13 4 Measures prior to extended shut down period 190 9 Setting up...

Page 9: ...1 Introduction Introduction BW 100 ADM 5 9...

Page 10: ...ntenance instructions before taking your machine into operation Please observe the safety regulations strictly and follow all instructions to ensure safe opera tion If you are not yet acquainted with...

Page 11: ...d fuels and lubri cants all warranty claims will become null and void For your own personal safety you should only use original parts from BOMAG For your machine we offer service kits to make maintena...

Page 12: ...late Please enter here Machine type 1 Serial number 2 Please enter here Engine type Fig 1 Engine number 2 Fig 1 Machine type plate example Fig 2 Engine type plate example Introduction Machine type pla...

Page 13: ...2 Technical data Technical data BW 100 ADM 5 13...

Page 14: ...8 1627 64 2304 91 255 10 0 2194 86 28 1 1 12 0 5 1000 39 Dimensions in millimetres Dimensions in inches Weights Max operating weight 1900 4189 kg lbs Operating weight 1700 3748 kg lbs Average static...

Page 15: ...0 Drive Engine manufacturer Kubota Type D902 Cooling Water Number of cylinders 3 Rated power ISO 14396 15 1 kW Rated power SAE J 1995 20 2 hp Rated speed 3000 min 1 Fixed engine speed 1 2100 min 1 Fix...

Page 16: ...g of drum to the right left 0 50 0 2 0 mm in Exciter system Vibrating drum front rear Drive system hydrostatic Frequency 1 2 42 63 2520 3780 Hz vpm Amplitude 0 40 0 016 mm in Centrifugal force 1 2 8 1...

Page 17: ...ng conditions 2 1 1 Noise data LpA 84 dB A determined acc to ISO 11201 and EN 500 WARNING Loss of hearing caused by too high noise burdens Wear your personal protective equipment ear protection LWA 10...

Page 18: ...Technical data Noise and vibration data BW 100 ADM 5 18...

Page 19: ...3 Concerning your safety Concerning your safety BW 100 ADM 5 19...

Page 20: ...y with these safety regula tions If necessary the operating company must obtain the relevant signatures as confir mation Furthermore the following obviously also applies n applicable accident preventi...

Page 21: ...ions marked accordingly indi cate a dangerous situation that could lead to fatal or severe injuries if this warning is disregarded CAUTION Danger of injury if failing to comply Sections marked accordi...

Page 22: ...uip ment is required to be provided by the operating company Working clothes Tight fitting working clothes with low tear resistance tight sleeves and without any projecting parts protect against being...

Page 23: ...or particles 3 1 4 Intended use This machine is intended for commercial use only The machine must only be used for n Compaction of bituminous material e g road surface layers n Compaction during eart...

Page 24: ...kerbs verges trenches pot holes n unauthorized use of public roads n Using the machine for towing Transporting persons except the machine driver is prohibited Starting and operating the machine in ex...

Page 25: ...t any remaining dangers The operating company must determine whether there are special operational hazards such as a toxic atmosphere or limiting soil con ditions Such conditions require special addi...

Page 26: ...y aged 18 or more Observe your local laws and regulations Rights obligations and rules of conduct for driver or operator The driver or operator must n be instructed about his rights and obliga tions n...

Page 27: ...actual danger zone of the machine Persons remaining in this area must pay partic ular attention to the machine so that they can react immediately in case of a possible mal function an incident or fai...

Page 28: ...ective 3 3 5 Roll Over Protective Structure ROPS The frame of the machine must not be warped bent or cracked in the area of the ROPS fas tening The ROPS must not show any rust damage hairline cracks o...

Page 29: ...me of substance n possible dangers n composition information on constituents n first aid measures n fire fighting measures n measures in case of accidental release n handling and storage n limitation...

Page 30: ...clothing CAUTION Health hazard caused by contact with diesel fuel Wear your personal protective equipment protective gloves protective clothing Do not inhale any fuel fumes Avoid contact CAUTION Dang...

Page 31: ...y bind spilled diesel fuel with an oil binding agent and dispose of properly Dispose of diesel fuel and fuel fil ters according to regulations Concerning your safety Handling fuels and lubricants BW 1...

Page 32: ...sed by contact with oil Wear your personal protective equipment protective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil Immediately...

Page 33: ...penetrate the skin immediate medical help is required WARNING Danger of burning by ignited hydraulic oil Do not allow hydraulic oil to come into contact with hot com ponents Smoking and open fire is...

Page 34: ...ding agent ENVIRONMENT Oil is an environmentally haz ardous substance Always keep oil in proper con tainers Immediately bind spilled oil with an oil binding agent Dispose of oil and oil filter accordi...

Page 35: ...ed by contact with coolant and coolant addi tives Wear your personal protective equipment protective gloves protective clothing Do not inhale any fumes Avoid contact CAUTION Danger of slipping on spil...

Page 36: ...ely bind spilled coolant with an oil binding agent and dis pose of it according to regula tions Dispose of coolant according to regulations Concerning your safety Handling fuels and lubricants BW 100...

Page 37: ...or eyes immediately with lots of clean water Immediately call for medical advice in case of cauterization WARNING Danger of injury caused by exploding gas mixture Remove the plugs before starting to...

Page 38: ...ENVIRONMENT Battery acid is an environmen tally hazardous substance Dispose of battery and battery acid according to regulations Concerning your safety Handling fuels and lubricants BW 100 ADM 5 38...

Page 39: ...impaired in any way Always use appropriate lashing tackle at the lashing points Use lashing tackle only in the specified loading direction Lashing tackle must not be damaged by machine parts Secure th...

Page 40: ...k again as otherwise the machine would not be steerable Operate the machine only with the ROPS folded up and the fastening screws tightened with the correct tightening torque Concerning your safety Lo...

Page 41: ...ting the machine check whether n persons or obstructions are beside or under the machine n the machine is free of oily and combustible materials n all access steps grips and platforms are free of obst...

Page 42: ...ilot or ether The machine must not be operated with dam aged missing or non functional safety installa tions After starting check all display instruments Do not inhale exhaust fumes because they conta...

Page 43: ...Do not start the engine by shorting the electric terminals on the starter motor because the machine may start to drive immediately Concerning your safety Starting up the machine BW 100 ADM 5 43...

Page 44: ...nd Do not adjust the driver s seat while driving Do not climb onto or off the machine while the machine is driving Do not use the machine to transport persons In the case of unusual noises and appeara...

Page 45: ...Soil conditions and weather influences impair the gradeability of the machine Wet and loose soil considerably reduces trac tion of the machine on inclinations and slopes Increased danger of accident 3...

Page 46: ...ildings and underground supply lines gas water sewage electric power If neces sary stop compacting with vibration Do not activate the vibration on hard frozen concrete ground Components may get dam ag...

Page 47: ...could be in the way with a clearly visible sign When parking on ascents or descents use appropriate means to secure the machine against rolling Concerning your safety Driving the machine working opera...

Page 48: ...charging than diesel fuel with a higher sulphur content You should therefore always make sure that the filling system is properly grounded and that there is equipotential bonding to the machine If nec...

Page 49: ...use the emergency stop switch as a service brake 3 9 2 Disconnecting the battery In events of emergency e g in case of a cable fire disconnect the battery from the vehicle network Pull out the main ba...

Page 50: ...ans are able to withstand the load and are fastened at the points pro vided for this purpose Before removing the towing facility apply appropriate measures to secure the machine against unintended rol...

Page 51: ...lic lines Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury Immediately call for medical assistance if injured by hydraulic oil Do not step in front of or behind the...

Page 52: ...operating temperature danger of scalding Wipe off spilled oil collect leaking oil and dis pose of it in an environmentally friendly way Store used filters and other oil contaminated materials in a sep...

Page 53: ...ing on the battery The connection cables of the battery must not touch or rub against machine parts 3 10 5 Cleaning work Do not perform cleaning work while the motor is running Allow the engine to coo...

Page 54: ...t both before and after shut down Chapter 8 13 4 Measures prior to extended shut down period on page 190 It is not necessary to define a maximum storage period if these measures have been performed 3...

Page 55: ...rning sign Only operate the machine after it has been repaired Repairs must only be performed by an expert qualified person When replacing safety relevant components only original spare parts must be...

Page 56: ...Signage Keep stickers and signage in good and legible condition and comply with their meaning Replace damaged and illegible stickers or sig nage immediately Concerning your safety Signage BW 100 ADM...

Page 57: ...WARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that are reproductive toxicants B 462 0013 Fig 10 Concerning your safety Signage BW 100 ADM 5 57...

Page 58: ...lant Spec MB 325 5 Deutz DQC CC 14 Hydraulic Oil 17 kg 50 Nm 008 303 29 1m 8 kg 80 Nm 30 cm Nm 50 80 ft lb 37 60 B 462 0014 Fig 11 Warning sticker Danger of tipping over B DEC 0206 Fig 12 Concerning y...

Page 59: ...cker Foldable ROPS Warning sticker California Proposition 65 Fig 13 Fig 14 B DEC 0207 Fig 15 WARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that...

Page 60: ...ker High pressure cleaning Instruction sticker Always wear your seat belt Information sticker Lifting point Information sticker Lashing point Fig 17 Fig 18 Fig 19 Fig 20 Concerning your safety Signage...

Page 61: ...il Information sticker Engine oil drain Information sticker Disconnecting the battery Information sticker Ultra low sulphur fuel B DEC 0214 Hydraulic Oil Fig 21 B DEC 0211 Fig 22 B DEC 0219 Fig 23 Fig...

Page 62: ...rmation sticker Low ash engine oil Information sticker Coolant Information sticker ECOSTOP Fig 25 Fig 26 B DEC 0221 Part No 009 940 03 20 l Engine Coolant Spec MB 325 5 Deutz DQC CC 14 Fig 27 B DEC 03...

Page 63: ...r Information sticker for the operation of the foldable ROPS Machine type plate example B DEC 0236 Fig 29 B DEC 0007 17 kg 50 Nm 1m 8 kg 80 Nm 30 cm Nm 50 80 ft lb 37 60 Fig 30 Fig 31 Concerning your...

Page 64: ...s a danger zone Before starting the machine and during opera tion the driver operator must ensure that nobody is in the danger zone Give warning signals if necessary Stop work immediately if persons a...

Page 65: ...4 Indicators and control elements Indicators and control elements BW 100 ADM 5 65...

Page 66: ...hazard light system optional equipment 5 Rotary switch for flashing beacon optional equipment 6 Rotary switch for hydraulic breaker optional equipment 7 Rotary switch for drum pre selection 8 Rotary...

Page 67: ...side are flashing Optional equipment 4 1 2 Rotary switch for working lights Position Left Working lights off Position Right Working light on 4 1 3 Rotary switch for lighting Position Left Light off P...

Page 68: ...flashing beacon Position Left Flashing beacon off Position Right Flashing beacon on Optional equipment 4 1 6 Rotary switch for the hydraulic hammer Position Left Hydraulic hammer off Position Right Hy...

Page 69: ...y switch for vibration pre selection Position left Pre selection vibration in manual mode Vibration is switched on or off via the vibration push button in the travel lever Position middle Vibration of...

Page 70: ...locks in end position The machine will be braked immediately The engine is shut down switch off unlock Turn the Emergency Stop switch clockwise and let it go NOTICE In case of frequent use the wear on...

Page 71: ...warning light Lights up when the driver s seat is not occu pied If the machine is travelling the warning buzzer will sound and the engine will be shut down after 2 seconds If the travel lever is shif...

Page 72: ...the engine Charge control light Lights up if the battery is not being charged Check the V belt if necessary repair the gen erator Indicator control light Parking brake warning light Lights up when the...

Page 73: ...pment 4 1 12 Rotary switch for seat heating Position left Seat heating off Position right Seat heating on The control light in the switch lights up Optional equipment 4 1 13 Rotary switch for water sp...

Page 74: ...5 4 6 1 2 B 462 0020 Fig 48 1 Starter switch 2 12 V DIN socket 3 Travel lever right 4 Driver s seat 5 Travel lever left optional equipment 6 Throttle lever Indicators and control elements Driver s st...

Page 75: ...key up to 10 seconds in position II Position III Turn further against spring pressure the engine starts Turn the ignition key back to position I when the engine starts The starter switch is designed w...

Page 76: ...el n Position I up to approx 5 km h 3 mph n Position II up to approx 10 km h 6 2 mph Pull back Backward travel n Position I up to approx 5 km h 3 mph n Position II up to approx 10 km h 6 2 mph Positio...

Page 77: ...ent depends on the machine s equip ment 1 2 3 4 B ELE 0303 1 Vibration on off 2 Warning horn 3 Lift edge cutter on right hand side optional equipment 4 Lower edge cutter on right hand side optional eq...

Page 78: ...rect driver s weight has been set Press down the handle against the end stop the weight adjustment automatically switches back to the top position 2 Length adjust ment Pull the lever up and push the s...

Page 79: ...e lever Position MIN Idle speed position Position MAX I Full load position I Position MAX II Full load position II MIN MAX II MAX I B 880 0159 Fig 53 Indicators and control elements Driver s stand BW...

Page 80: ...4 3 3 Main battery switch Position on Main battery switch locked Normal position operation Turn anticlock wise Main battery switch can be pulled out Disconnects the batteries from the on board electri...

Page 81: ...seat belt Seat belt fastened Warning indicator for seat belt on Seat belt not fas tened Warning indicator for seat belt off Optional equipment B 880 0222 Fig 57 Indicators and control elements Outside...

Page 82: ...Indicators and control elements Outside of machine BW 100 ADM 5 82...

Page 83: ...5 Checks prior to start up Checks prior to start up BW 100 ADM 5 83...

Page 84: ...and lubricants Safety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Chapter 3 4 Handling fuels and lubri cants on page 29 WARNING Danger of...

Page 85: ...pen and secure the engine hood Chapter 8 2 1 1 Open and secure the engine hood on page 142 Close the engine hood again after work is com pleted Checks prior to start up Notes on safety BW 100 ADM 5 85...

Page 86: ...heck the bolted connections are tight and secure 5 Check the engine and exhaust system for leaks 6 Check the belt drive for damage 7 Check the machine for contamination and damage 8 Check function of...

Page 87: ...afety shoes n Protective gloves 1 Pull the dipstick out wipe it off with a lint free clean cloth and reinsert it to the end stop 2 Pull the dipstick out again The oil level must be between the MIN and...

Page 88: ...ge 2 Check the filling level at the fuel level indi cator optional equipment in the instru ment cluster 3 Refuel if required but only after shutting down the engine first Fuel level gauge B 462 0023 F...

Page 89: ...n or even damage of the engine If necessary fill in fuel through a screen filter Use only fuel of the permitted specification Chapter 8 3 2 Fuel on page 146 Protective equip ment n Working clothes n S...

Page 90: ...il of the permitted specification Chapter 8 3 4 Hydraulic oil on page 149 Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Check the oil level in the inspection glass Norma...

Page 91: ...age 148 Protective equip ment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 WARNING Danger of scalding by hot fluid Open the compensation tank only when the engine is cold We...

Page 92: ...he air filter Chapter 8 13 1 Air filter maintenance on page 184 5 3 6 Checking the water level topping up Protective equip ment n Working clothes n Safety shoes n Protective gloves NOTICE Components m...

Page 93: ...e filling level on the water level gauge fill up if necessary 2 Unscrew the cap 1 and fill in clean water through the strainer 2 3 Make sure that the ventilation bore in the filler cap is clear 4 Clos...

Page 94: ...o nents Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components Protective equip ment n Working clothes n Safety shoes n Protective gloves The maint...

Page 95: ...on the left hand side of the machine if the pin of the maintenance indicator has popped out 8 Check the maintenance indicator at max imum engine speed 9 If the pin is visible press it in Should the p...

Page 96: ...e damage Do not shut down the engine all of a sudden from full load speed but let it idle for about two minutes Turn the ignition key to position 0 B ELE 0069 Fig 71 Checks prior to start up Daily mai...

Page 97: ...6 Operation Operation BW 100 ADM 5 97...

Page 98: ...ace 1 Park the machine safely Chapter 6 9 Parking the machine in secured condition on page 117 2 If necessary adjust the driver s seat Chapter 4 2 4 Driver s seat on page 78 Operation Setting up the w...

Page 99: ...mobilizer armed the light emitting diode a flashes slowly 1 Slowly enter the six digit user code When entering the code the light emit ting diode 6 lights up with every digit 2 Press the diamond butto...

Page 100: ...requisites n Main battery switch if present switched on n Emergency stop switch is unlocked n Travel lever in parking brake position When closing the dashboard cover the emergency stop switch will loc...

Page 101: ...nition key must first be turned back to position 0 before a new starting attempt can be made NOTICE Components may get dam aged Run the starting process for maximum 20 seconds without interruption and...

Page 102: ...NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immediately under full load Operation Starting the engine BW 100 ADM 5 102...

Page 103: ...he machine Wet and loose soil considerably reduces trac tion of the machine on inclinations and slopes Greater danger of accident When driving up and down slopes move the travel lever slowly back towa...

Page 104: ...r optional equipment to the Left position 3 Set the throttle lever to position MAX I or MAX II 4 Disengage the travel lever out of braking position and move it slowly to the required travel direction...

Page 105: ...Middle position and engage it in parking brake position The machine will decelerate down to a standstill and the parking brake will be applied after approx 2 seconds The parking brake warning light li...

Page 106: ...hine in secured condition on page 117 2 Check the lighting 3 If necessary dismantle the tool pressure roller cutting wheel on the edge cutter optional equipment and remove the star handle screw Chapte...

Page 107: ...tion The further the travel lever is moved for wards or backwards the faster the machine will travel Stick to the maximum speed of 8 km h 5 mph 10 Set the travel lever to Middle position to stop the m...

Page 108: ...ion on hard frozen concrete ground Vibration at standstill causes transverse marks n Switch the vibration on only after the machine has reached its nominal speed n Switch the vibration off approx one...

Page 109: ...n is only acti vated if the vibration has been switched off beforehand 2 Set the throttle lever to position MAX I or MAX II 6 6 3 Manual vibration 1 Turn the rotary switch for vibration pre selection...

Page 110: ...e again to switch off vibration 6 6 4 Vibration in automatic mode 1 Turn the rotary switch for vibration pre selection to position Right 2 Shift the travel lever slowly in the desired travel direction...

Page 111: ...e detection and selected re compaction of weak spots The acceleration transducer on the front drum measures the reaction of the road subbase on the vibrating drum The ECONOMIZER is automatically start...

Page 112: ...the vibration motor has reached its nominal frequency n flashes if the drum is in jump operation n lights in case of faults Chapter 10 5 Trouble shooting ECONOMIZER on page 210 In order to achieve the...

Page 113: ...The measuring values achieved with different tandem vibratory rollers can be made compa rable by calibration to a reference value Operation Working with vibration BW 100 ADM 5 113...

Page 114: ...he travel lever is actuated in travel direction or after the rotary switch for the water spraying system has been set to permanent spraying position MAX With the travel lever in neu tral spraying will...

Page 115: ...el lever has been moved out of parking brake position once after engine start n Travel lever in parking brake position n Driver s seat not occupied n Engine on NOTICE The battery can become partly or...

Page 116: ...1 Turn the ignition key to position 0 2 Start the engine Chapter 6 3 Starting the engine on page 100 Starting the engine after ECOSTOP B ELE 0069 Fig 97 Operation ECOSTOP BW 100 ADM 5 116...

Page 117: ...er approx 2 seconds The parking brake warning light lights up 3 Shift the throttle lever to position MIN idle speed 4 NOTICE Danger of engine damage Do not shut down the engine all of a sudden from fu...

Page 118: ...5 Turn the main battery switch if present anticlockwise and pull it out B SWI 0079 Fig 102 Operation Parking the machine in secured condition BW 100 ADM 5 118...

Page 119: ...button on the right travel lever The edge cutter is lowered 2 Press the top push button on the right travel lever The edge cutter is raised If the water spraying system is switched on the edge cutter...

Page 120: ...on and engage it to the right into parking brake position 2 Turn the ignition key to position 0 and pull it out 3 Turn the rotary switch for hydraulic hammer to the Left position Connecting the hydrau...

Page 121: ...age 100 6 Turn the rotary switch for hydraulic hammer to the Right position 7 Set the throttle lever to position MAX II The hydraulic breaker can now be used B 462 0033 Fig 107 B SWI 0696 Fig 108 MIN...

Page 122: ...he engine all of a sudden from full load speed but let it idle for about two minutes Turn the ignition key to position 0 and pull it out 11 Disconnect the hydraulic hammer from the couplings Disconnec...

Page 123: ...danger e g cable fire the minus ter minal has been designed as a quick release pole clamp Alternatively the machine can be equipped with a main battery switch optional equipment 1 Open the maintenanc...

Page 124: ...nly out of the direct danger zone towing speed 1 km h 0 6 mph Before towing make sure that n the tractor vehicle has sufficient traction and braking power for the non braking towed load n tow bar and...

Page 125: ...owing eye WARNING Danger of injury caused by uncontrolled machine movement Always secure the machine against unintended rolling 4 Remove two plugs 5 Press both screws in against the springs 6 Tighten...

Page 126: ...nt n Working clothes n Safety shoes n Protective gloves WARNING Danger of injury caused by uncontrolled machine movement Always secure the machine against unintended rolling 1 After towing park the ma...

Page 127: ...lease both screws to close the brake 4 Screw both plugs back in tightening torque 50 Nm 37 ft lbf 5 Close also the brake on the second drum Fig 121 B 880 0014 Fig 122 Operation Emergency procedures BW...

Page 128: ...Operation Emergency procedures BW 100 ADM 5 128...

Page 129: ...7 Loading transporting the machine Loading transporting the machine BW 100 ADM 5 129...

Page 130: ...cutter optional equipment and remove the star handle screw Chapter 9 2 Edge cutter mounting and removing tools on page 198 2 Close all flaps 3 Remove all loose objects from the machine or the driver s...

Page 131: ...ine 1 Fasten your seat belt 2 Set the throttle lever to position MAX I DANGER Danger to life caused by the machine slipping or turning over Make sure that no persons are in the danger zone 3 Drive the...

Page 132: ...ified loading direction Lashing tackle must not be damaged by machine parts Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Fasten the lifting and lashing tackle on the ma...

Page 133: ...ing points Use lifting and lashing gear only in the pre scribed direction of load application Lifting tackle must not be damaged by machine components When lifting the machine avoid uncontrolled movem...

Page 134: ...tackle 5 DANGER Danger to life caused by sus pended loads Do not step or stand under suspended loads Lift the machine carefully and set down again at the intended location B 880 0261 Fig 125 Loading...

Page 135: ...age 144 3 Fasten your seat belt 4 Set the throttle lever to position MAX I DANGER Danger to life caused by the machine slipping or turning over Make sure that no persons are in the danger zone 5 Drive...

Page 136: ...t n Working clothes n Safety shoes n Protective gloves 1 Loosen the eye bolts on both sides 2 CAUTION Head injuries caused by folding the foldable ROPS Do not step into the slewing area of the foldabl...

Page 137: ...S Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Erect the clamping plates on both sides vertically B 462 0041 Fig 129 B 462 0045 Fig 130 Loading transporting the machine...

Page 138: ...Fold up the foldable ROPS 3 Erect the clamping plates on both sides horizontally 4 Tighten the eye bolts on both sides tight ening torque 50 80 Nm 37 60 ft lbf B 462 0042 Fig 131 B 462 0046 Fig 132 50...

Page 139: ...8 Maintenance Maintenance BW 100 ADM 5 139...

Page 140: ...fety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Chapter 3 4 Handling fuels and lubri cants on page 29 CAUTION Danger of being injured by...

Page 141: ...use the access steps and working platforms provided or other secure means Do not step on machine parts which are not intended for this purpose Always attach the articulation lock when working in the a...

Page 142: ...all maintenance flaps and doors again and return all components to their operating condition 8 2 1 Engine hood 8 2 1 1 Open and secure the engine hood 1 Open the locking 2 Push the hood to top positi...

Page 143: ...ap downwards by the handle 2 Insert the bottle holder 8 2 3 Articulation lock 8 2 3 1 Engaging the articulation lock Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Move t...

Page 144: ...iculation lock Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Switch off the engine and remove the igni tion key 2 WARNING Danger of crushing by the articulating machine...

Page 145: ...scosity Since engine oil changes its viscosity with the temperature the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class SAE class...

Page 146: ...oil change intervals must be halved 8 3 2 Fuel 8 3 2 1 Fuel quality We recommend using a diesel fuel with a sul phur content of less than 0 1 When using a diesel fuel with a high sulphur content of 0...

Page 147: ...nly winter diesel fuel to avoid clogging because of paraffin separa tion At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel Diesel fuels suitabl...

Page 148: ...ypes of anti freeze agents available For this engine you should use eth ylene glycol Before filling in the coolant mixed with anti freeze agent the radiator must be flushed with clean water This proce...

Page 149: ...agent it may cause the development of sludge which could damage the cooling system Anti freeze concen tration Freezing point 50 37 C 35 F 8 3 4 Hydraulic oil 8 3 4 1 Mineral oil based hydraulic oil Th...

Page 150: ...op up and do not mix oil types When changing from mineral oil based hydraulic oil to an ester based biologically degradable hydraulic oil you should consult the lubrication oil service of the oil manu...

Page 151: ...ter 8 3 2 Fuel on page 146 Coolant Mixture of water and anti freeze agent Specification Chapter 8 3 3 Coolant on page 148 009 940 03 20 l 9 l 2 4 gal us Hydraulic system Hydraulic oil ISO HVLP 46 Spec...

Page 152: ...engine oil level twice every day Depending on the load the engine is subjected to the oil consumption will drop to the normal level after approx 100 to 250 operating hours 8 5 2 After 50 operating ho...

Page 153: ...and cleaning the water separator 155 Every 250 operating hours 8 8 1 Change engine oil and oil filter cartridge 157 8 8 2 Checking tensioning the V belt 159 8 8 3 Check the air intake lines 160 8 8 4...

Page 154: ...filter 177 8 11 3 Changing the coolant 179 8 11 4 Replacing hoses 182 8 11 5 Checking the injection nozzles 182 Every 3000 operating hours 8 12 1 Checking the exhaust gas recirculation system 183 As r...

Page 155: ...e found to be damaged the corresponding parts must be immediately repaired or replaced by authorized service personnel NOTICE Danger of engine damage After work on the fuel system bleed the system per...

Page 156: ...sparent container under the drain plug 3 Loosen the drain plug and drain the fluid until pure diesel fuel starts to run out 4 Collect the escaping fluid 5 Screw the drain plug back in tightly Check fo...

Page 157: ...ersonal protective equipment protective gloves protective clothing Avoid touching hot components NOTICE Danger of engine damage Change the oil only with the engine at operating temperature Use only oi...

Page 158: ...drain plug back in tightly 5 Thoroughly clean the outside of the oil filter cartridge 6 Unscrew the oil filter cartridge using an appropriate strap wrench 7 Remove any dirt from the sealing face of th...

Page 159: ...king clothes n Protective gloves 1 Park the machine in secured condition Chapter 6 9 Parking the machine in secured condition on page 117 2 Allow the engine to cool down 3 Check the entire circumferen...

Page 160: ...in secured condition Chapter 6 9 Parking the machine in secured condition on page 117 2 Allow the engine to cool down 3 Check the condition and tight fit of all air intake lines and hose clamps 4 If...

Page 161: ...st be replaced immediately 8 8 5 Cleaning the radiator module NOTICE Components may get damaged Do not bend or damage cooling fins Do not clean with high pressure 1 Park the machine in secured conditi...

Page 162: ...around Wear your personal protective equipment safety gloves protec tive working clothes goggles 1 Blow the cooler out with compressed air from inside the engine compartment 2 Blow the cooler out wit...

Page 163: ...rong water jet 2 Run the engine warm for a while to avoid corrosion 8 8 6 Battery service Maintenance free batteries also need care Maintenance free only means that the fluid level does not need to be...

Page 164: ...battery and clean the battery compartment 3 Clean the outside of the battery 4 Clean the battery poles and terminals and grease them with pole grease Vaseline 5 Install the battery and check the batte...

Page 165: ...ug and collect leaking fuel 4 Screw the drain plug firmly back in with a new seal ring tightening torque 6 8 Nm 4 5 6 ft lbf 5 Fill the fuel tank with clean fuel 6 Dispose of fuel in line with environ...

Page 166: ...and observe the flow direction arrow 5 Unscrew the drain plug and collect the escaping fuel 6 Unscrew the filter 7 Remove any dirt from the sealing face of the filter carrier 8 NOTICE Danger of engin...

Page 167: ...short test run 14 Dispose of fuel and filter element in line with environmental regulations 8 9 3 Replacing the V belt Perform this maintenance work at the latest after two years Protective equip men...

Page 168: ...ne in secured condition Chapter 6 9 Parking the machine in secured condition on page 117 2 Allow the engine to cool down 3 Remove the cover 1 from the compensa tion tank and check the anti freeze conc...

Page 169: ...ion formation of blisters crushed spots buckling n leaks on hose socket or fitting n the hydraulic hose has separated from the fitting n fittings are damaged or deformed whereby the function and stren...

Page 170: ...engine cool down for at least 30 minutes The engine oil temperature must be below 80 C 176 F Valve clearance Intake exhaust valve 0 15 mm 0 006 in Protective equip ment n Working clothes n Safety shoe...

Page 171: ...ther 6 Check the valve clearance on the valves marked black adjust if necessary 7 Install the cylinder head cover with a new seal 8 After a short test run check the engine for leaks 1 2 3 I E I E I E...

Page 172: ...in secured condition Chapter 6 9 Parking the machine in secured condition on page 117 2 Allow the engine to cool down 3 Check air intake and exhaust manifold fas tenings for tight fit 4 Check sockets...

Page 173: ...must comply with the specifications and should be absolutely tight observe the tightening torques Screw and nuts must not be damaged bent or deformed Unusual movements and noises vibrations during ope...

Page 174: ...hydraulic oil Do not use any detergents to clean the system Use only lint free cleaning cloths for cleaning When changing from mineral oil based hydraulic oil to an ester based biologically degradable...

Page 175: ...the cover from the hydraulic oil tank 4 WARNING Danger of burning on hot components Wear your personal protec tive equipment protective gloves protective clothing Avoid touching hot compo nents Unscr...

Page 176: ...nest filtration of the hydraulic oil prolongs the life time of the hydraulic oil filter and protects the hydraulic system Fill in new hydraulic oil 10 Check the hydraulic oil level in the inspec tion...

Page 177: ...h the hydraulic oil the filter must only be changed after the oil change and after the test run Do not use the oil in the filter housing again Apart from the normal oil change intervals the filter ele...

Page 178: ...ermine the cause and replace or repair the defec tive components if necessary Do not clean or reuse the filter element 2 Take out the filter element 1 and clean the filter housing 3 Clean the thread o...

Page 179: ...8 11 1 Changing the hydraulic oil on page 174 3 Dispose of the hydraulic oil and filter in line with environmental regulations 8 11 3 Changing the coolant Perform this maintenance work at the latest...

Page 180: ...engine damage Use only coolant of the permitted specification Chapter 8 3 3 Coolant on page 148 Do not mix different coolants and additives of any other kind Filling quantity Chapter 8 4 List of fuels...

Page 181: ...until the level reaches the bottom edge of the filler socket 11 Screw the cover back on again 12 Fill in coolant up to the MAX mark on the compensation tank 13 Close the cap 14 Start the engine and ru...

Page 182: ...rsonnel Perform this maintenance work at the latest after two years The following hoses need to be renewed n fuel hoses n air intake hoses n hoses in connection with the oil separator 8 11 5 Checking...

Page 183: ...2 Every 3000 operating hours 8 12 1 Checking the exhaust gas recirculation system This work must only be performed by authorized service personnel Maintenance Every 3000 operating hours BW 100 ADM 5 1...

Page 184: ...air filter must be inspected for damage using a torch Do not continue to use a dam aged air filter element If in doubt use a new air filter Protective equip ment n Working clothes n Safety shoes n Pr...

Page 185: ...n the filter housing thoroughly CAUTION Danger of eye injuries caused by particles flying around Wear your personal protective equipment safety gloves protec tive working clothes goggles 8 Blow the ai...

Page 186: ...g NOTICE Danger of engine damage The dust discharge valve must point vertically downwards Make sure that the cover locks engage correctly 12 Reinstall the cover 13 After maintenance has been completed...

Page 187: ...hine in secured condition on page 117 2 Remove the cap 1 3 Take the filling screen 2 out and clean it 4 Check the filling screen for damage replace if necessary 5 Close the cap 6 Open the rear door 7...

Page 188: ...nants out of the lines 14 Switch off the water spraying system 15 Turn the ignition key back to position 0 and pull it out 16 Reinstall all caps and nozzles 8 13 3 Measures if there is a risk of frost...

Page 189: ...g pump to the outside 9 Open the drain valve and drain off all water 10 Switch on the water spraying system for a short while to drain the water from the pump 11 Switch off the water spraying system 1...

Page 190: ...Grease the bare piston rods of all hydraulic cylinders well and pull them in as far as possible 4 Spray a thin oil film onto to all lever joints and bearing points without lubrication 5 Repair damaged...

Page 191: ...Smoking and open fire is pro hibited Do not lay any tools or other metal objects on the battery Do not wear jewellery watch bracelets etc when working on the battery Wear your personal protective equi...

Page 192: ...lways disconnect the battery Do not forget to perform regular open circuit voltage measurements 8 13 4 3 Measures before restarting 1 Replace the fuel filter 2 Replace the air filter 3 Change engine o...

Page 193: ...keep an eye on the gauges for engine oil pressure and coolant temperature 12 Check the oil levels 13 Check the function of electric system steering and brakes 14 Clean the machine thoroughly Maintenan...

Page 194: ...Maintenance As required BW 100 ADM 5 194...

Page 195: ...9 Setting up refitting Setting up refitting BW 100 ADM 5 195...

Page 196: ...lashing tackle only in the specified loading direction Lashing tackle must not be damaged by machine parts Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Park the machin...

Page 197: ...just above the ground 6 Shift the rear frame to the desired position on the left or right 7 Lower the machine to the ground 8 Tighten the screws 1 again tightening torque 300 Nm 221 ft lbf B 880 0261...

Page 198: ...lic traffic disassemble the tool from the edge cutter and holding fixture and remove the star handle screw Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Park the machine...

Page 199: ...3 Use the star handle nut to mount the tools to or remove them from the holding fixture B 462 0071 Fig 195 Setting up refitting Edge cutter mounting and removing tools BW 100 ADM 5 199...

Page 200: ...Setting up refitting Edge cutter mounting and removing tools BW 100 ADM 5 200...

Page 201: ...10 Troubleshooting Troubleshooting BW 100 ADM 5 201...

Page 202: ...Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance If you cannot locate the cause of a fault or rec tify it yourself by following the...

Page 203: ...ngine or chassis ground as far away from the bat tery as possible 3 Start the engine Chapter 6 3 Starting the engine on page 100 NOTICE Danger of damage to the elec tronic system If no powerful consum...

Page 204: ...central electrics against the end stop The printed circuit board is equipped with a fuse test socket Fuse Test When plugging in an intact fuse an LED lights up Fuse Amperage Designation F241 15 A Opt...

Page 205: ...Engine solenoid F275 5 A Economizer F48 40 A Preheating system F10 10 A Parking and tail light right F09 10 A Parking and tail light left F157 30 A Starter F45 10 A Edge cutter F37 10 A Water pump F0...

Page 206: ...Fuse Amperage Designation F00 80 A Main fuse Troubleshooting Fuse assignment BW 100 ADM 5 206...

Page 207: ...ty or runs irregu larly at low power Battery power is too low con nection terminals are loose and oxidised causing the starter to rotate slowly Check the battery charge clean and tighten the connec ti...

Page 208: ...o low Check refill if necessary Lack of coolant Check all lines hoses and engine for condition and leaks Check the coolant level refill if necessary Do not use radiator sealant to seal leaks Anti free...

Page 209: ...oo low Check refill if necessary The charge control light lights up during opera tion warning buzzer sounds Generator speed too low Check the tension of the gen erator belt if necessary replace the be...

Page 210: ...n sensor Cable breakage Inform our Customer Service Department LED a lights up The Economizer is unable to read a calibration value when starting Since this value is required for calculation the measu...

Page 211: ...ews of the acceleration sensor Weak spots in the road sub base are also measured when paving asphalt In unfavourable cases an excessively varying material composition or moisture in the road subbase c...

Page 212: ...Troubleshooting Trouble shooting ECONOMIZER BW 100 ADM 5 212...

Page 213: ...11 Disposal Disposal BW 100 ADM 5 213...

Page 214: ...hazard caused by fuels and lubricants Safety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Chapter 3 4 Handling fuels and lubri cants on pag...

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